Filtration media packs comprising plurality of bosses between filter media, filter elements, and methods for manufacturing

ABSTRACT

The present disclosure relates to filtration media packs, filter elements, and methods for manufacturing filtration media packs and filter elements. The present disclosure is directed to filtration media packs having alternating first media sheet and second media sheet secured together and forming a first flow face and a second flow face, wherein the first media sheet and the second media sheet provide a first separation or gap therebetween as a result of the presence of a first plurality of protrusions or bosses extending from at least one of the first media sheet or the second media sheet, and a second separation or gap therebetween as a result of a second plurality of protrusions or bosses extending from at least one of the first media sheet or the second media sheet, and the media pack being closed to passage of unfiltered fluid therethrough from the first flow face to the second flow face or from the second flow face to the first flow face without filtering passage through the first media sheet or the second media sheet.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is being filed on 10 Nov. 2015 as a PCT InternationalPatent Application and claims the benefit of U.S. Patent ApplicationSer. No. 62/077,749, filed on Nov. 10, 2014, and U.S. Patent ApplicationSer. No. 62/187,458, filed on Jul. 1, 2015, the disclosures of which areincorporated herein by reference in their entireties.

TECHNICAL FIELD

The present disclosure relates to filtration media packs, filterelements, and methods for manufacturing filtration media packs andfilter elements. The present disclosure is directed to filtration mediapacks having alternating first media sheet and second media sheetsecured together, and forming a first flow face and a second flow face.The alternating first media sheet and second media sheet provide a firstseparation or gap therebetween as a result of the presence of a firstplurality of protrusions or bosses extending from at least one of thefirst media sheet or the second media sheet, and a second separation orgap therebetween as a result of a second plurality of protrusions orbosses extending from at least one of the first media sheet or thesecond media sheet. The media pack is closed to passage of unfilteredfluid therethrough from the first flow face to the second flow face orfrom the second flow face to the first flow face without filteringpassage through the first media sheet or the second media sheet.

BACKGROUND

Fluid streams, such as air streams, often carry contaminant material. Inmany instances, it is desirable to filter some or all of the contaminantmaterial from the fluid streams. For example, particulate contaminantscan be carried by air streams into internal combustion engines formotorized vehicles or for power generation equipment. It is preferredfor such systems that selected contaminant material, such as particulatecontaminants, be removed from, or have its level reduced in, the airstream. Also liquid streams in the engine lubrication systems, hydraulicsystems, coolant systems, and fuel systems, can carry particulatecontaminant that should be filtered. It is preferred for such systemsthat the fluid streams are free from select contaminant material or havethe level of contaminant material therein reduced. A variety of fluidfilter arrangements (air or liquid filter) have been developed forcontaminant reduction.

Many filter arrangements include pleated or folded filtration media.Pleated or folded filtration media packs have a tendency to benon-self-supporting. Typically, some type of structure is used tosupport or stabilize the pleats of the pleated media pack. Furthermore,the filter media density of a pleated filtration media pack typicallyrefers to the number of pleat faces per unit distance, and is oftenlimited to reduce the occurrence of pleat faces contacting each other.Pleat faces that contact each other have a tendency to create masking orloss of filtration media effectiveness at the areas of contact.Exemplary pleated filtration media packs are disclosed, for example, inU.S. Pat. Nos. 8,216,335; 6,652,614; 8,603,210; 7,070,642; 4,963,171;and 5,125,941.

Another type of filtration media pack provided to address some of theshortcomings of pleated filtration media packs are referred to as flutedfiltration media packs or z-filtration media packs. Exemplaryz-filtration media packs are disclosed in, for example, U.S. Pat. Nos.5,562,825; 5,049,326; 5,895,574; and 4,925,561. Such z-filtration mediapacks typically include alternating fluted media sheet and facing mediasheet, and form a first flow face and a second flow face. Whilez-filtration media packs tend to be self-supporting and can provide forincreased media density relative to certain pleated filtration mediaarrangements, z-filtration media packs have a tendency to suffer frommasking at the locations where the fluted media sheet contacts thefacing media sheet.

Continued improvement in the design of filtration media packs and filterelements is desired in order to provide improved properties includingcontaminant loading, longevity, compactness, media density, and fluidflow properties.

SUMMARY

The present disclosure is directed to a filter media pack. The filtermedia pack includes a media construction comprising a first media sheetand a second media sheet secured together and forming a first flow faceand a second flow face, wherein each of the first media sheet and secondmedia sheet includes a first side and a second side.

In a first embodiment of a filter media pack, the first media sheetincludes a plurality of first bosses extending from the first mediasheet first side toward the second media sheet to provide a firstseparation between the first media sheet first side and the second mediasecond side, and the second media sheet includes a plurality of secondbosses extending from the second media sheet first side in a samedirection as the plurality of bosses on the first media sheet to providea second separation between the second media sheet first side and thefirst media sheet second side. The first media sheet and the secondmedia sheet are secured together at a first location to form the firstseparation open at the second flow face, and the first media sheet andthe second media sheet are secured together at a second location to formthe second separation open at the first flow face. The mediaconstruction is closed to the passage of unfiltered fluid therethroughfrom the first flow face to the second flow face, or from the secondflow face to the first flow face without a filtering passage through thefirst media sheet or the second media sheet.

In one or more variations of the first embodiment, the first media sheetcan include a plurality of third bosses extending from the first mediasheet second side in an opposite direction as the plurality of firstbosses to provide separation between the first media sheet second sideand the second media sheet first side.

In one or more variations of the first embodiment, the second mediasheet includes a plurality of fourth bosses extending from the secondmedia sheet second side in an opposite direction as a plurality of firstbosses to provide separation between the second media sheet second sideand the first media sheet first side.

In an alternative filter media pack (referred to as a secondembodiment), the first media sheet including a plurality of first bossesextending from the first media sheet first side toward the second mediasheet to provide a first separation between the first media sheet firstside and the second media sheet second side, and a plurality of secondbosses extending from the first media sheet second side in a directionopposite the plurality of first bosses to provide a second separationbetween the first media sheet second side and the second media sheetfirst side. The first media sheet and the second media sheet securedtogether at a first location to form the first separation open at thesecond flow face, and the first media sheet and the second media sheetsecured together at a second location to form the second separation openat the first flow face. The media construction being closed to passageof unfiltered fluid therethrough from the first flow face to the secondflow face or from the second flow face to the first flow face withoutfiltering passage through the first media sheet or the second mediasheet.

In one or more variations of the second embodiment, the second mediasheet can include a plurality of third bosses extending from the secondmedia sheet first side in a same direction as the plurality of firstbosses to provide separation between the second media sheet first sideand the first media sheet second side.

In one or more variations of the second embodiment, the second mediasheet includes a plurality of fourth bosses extending from the secondmedia sheet second side in an opposite direction as a plurality of firstbosses to provide separation between the second media sheet second sideand the first media sheet first side.

In the various embodiments, the first media sheet and the second mediasheet may each include a first edge that forms the first flow face and asecond edge that forms the second flow face. The first location forsecuring the first media to the second media sheet extends proximate thefirst edge, and the second location for securing the first media sheetand the second media sheet extend proximate the second edge.

The above can include a combination or sub-combination of any of thefeatures as described above and as described below. Example combinationsshould not be limited to including only those combinations. Indeed,advantages can be achieved from various sub-combinations of features.

Filter elements and methods of making filter media, media packs, andfilter elements are described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of a media sheetusable for forming a filter media pack, constructed in accordance withprinciples of this disclosure;

FIG. 2 is a cross-sectional view of the media sheet of FIG. 1, thecross-section being taken along the line 2-2 of FIG. 1;

FIG. 3 is a perspective view of another embodiment of a media sheetusable for forming a media pack, constructed in accordance with theprinciples of this disclosure;

FIG. 4 is a cross-sectional view of the media sheet of FIG. 3, thecross-section being taken along the line 4-4 of FIG. 3;

FIG. 5 is a perspective view of another embodiment of a media sheetusable for making a media pack, constructed in accordance withprinciples of this disclosure;

FIG. 6 is a cross-sectional view of the media sheet of FIG. 5, thecross-section being taken along the line 6-6 of FIG. 5;

FIG. 7 is a portion of a media pack formed from the media sheet of FIG.1 alternating with a flat media sheet;

FIG. 8 is a portion of a media pack using alternating media sheets ofFIGS. 3 and 5;

FIG. 9A is a schematic, perspective view of a filter media pack madefrom the construction of FIG. 7 and showing a first flow face;

FIG. 9B is an enlarged view of a portion of the flow face of FIG. 9A;

FIG. 9C is an schematic, perspective view of the filter media pack ofFIG. 9A, but showing the second, opposite flow face;

FIG. 9D is an enlarged view of a section of the flow face of FIG. 9C;

FIG. 10 is a schematic, perspective view of a method of forming themedia pack of FIGS. 9A and 9C;

FIG. 11 is an example embodiment of a media construction made from twosheets of the media sheet of FIG. 1, constructed in accordance withprinciples of this disclosure.

FIG. 12 is a sectional view of an exemplary boss, projection, or dimplein a media sheet in accordance with the principles of this disclosure;

FIG. 13 is a sectional view of an exemplary air cleaner that can includea filter element containing the filter media pack according to theprinciples of this disclosure;

FIG. 14 is a partial, sectional view of a filter element containing afilter media pack according to the principles of this disclosure;

FIG. 15 is a perspective view of a filter element containing a filtermedia pack according to the principles of this disclosure;

FIG. 16 is a perspective view of a filter element containing a filtermedia pack according to the principles of this disclosure;

FIG. 17 is a bottom, perspective view of the filter element of FIG. 16;

FIG. 18 is a side view of the center board of the filter element ofFIGS. 16 and 17;

FIG. 19 is a partial, sectional view of a filter arrangement containinga filter media pack according to the principles of this disclosure;

FIG. 20 is a partial, sectional view of an air cleaner having a filterelement containing a filter media pack according to the principles ofthis disclosure;

FIG. 21 is a perspective view of an exemplary element containing afilter media pack according to the principles of this disclosure;

FIG. 22 is a perspective view of an exemplary filter element containinga filter media pack according to the principles of this disclosure;

FIG. 23 is a partial sectional view of an exemplary liquid filteraccording to the principles of this disclosure; and

FIG. 24 is a partial sectional view of an exemplary liquid filteraccording the principles of this disclosure.

DETAILED DESCRIPTION

The disclosure relates to filtration media packs, filter elements orcartridges, and methods for manufacturing filtration media packs andfilter elements or cartridges. In general, filtration media can bereferred to more simply as “filter media” or “media” and refers to asubstrate that is used for filtering particulate contaminants from afluid stream. The fluid stream can be a gas stream or a liquid stream.An exemplary gas stream includes air, and the air can be provided forair intake for engines for motor vehicles, power generation equipment,combustion furnaces, HVAC, and for enclosed environments whereparticulates should be removed, such as work and home environments andclean rooms. The gas stream can also be a gas stream such as a gasstream to a gas turbine system. Exemplary liquid streams include enginelubrication systems, hydraulic systems, coolant systems, fuel systems,and water.

The filtration media pack can be formed from alternating layers of afirst media sheet and a second media sheet. The alternating layers ofthe first media sheet and the second media sheet can be provided byrepeating layers of single facer media. In general, single facer mediarefers to a combination of the first media sheet and the second mediasheet. The single facer media can be arranged as repeating layers toprovide the alternating first media sheet and second media sheet. In themedia pack, the alternating first media sheet and second media sheetprovide a first separation or gap therebetween to allow fluid to flowthrough the first separation or gap, and a second separation or gaptherebetween to allow fluid to low through the second separation or gap.The media pack can be characterized as a coiled arrangement or as astacked arrangement. In the case of a coiled arrangement, a length ofthe single facer media can be coiled or wound or rolled to form themedia pack. The coiled arrangement can be referred to as a woundarrangement or as a rolled arrangement. In the case of a stackedarrangement, the single facer media can be cut into lengths that arestacked on top of one another to form a media pack. Exemplary coiled andstacked arrangements in the context of fluted filtration media packs orz-filtration media packs are disclosed, for example, in U.S. Pat. Nos.5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469;6,190,432; 6,350,296; 6,179,890; 6,235,195; 5,895,574; Des. 399,944;Des. 428,128; Des. 396,098; Des. 398,046; and Des 437,401; each of thesesixteen cited references being incorporated by reference. In the contextof such fluted filtration media packs or z-filtration media packs, theseparation between the alternating sheets of media are typicallyprovided primarily as a result of the amplitude or height of the flutesof the alternating fluted sheet. In contrast, media packs according tothis disclosure provide separation as a result of bosses extending fromone or more of the first and/or second media sheets. The bosses can alsobe referred to as protrusions or dimples or bumps and are formed as aresult of deformation of the first and/or second media sheets.Alternatively, the bosses can be formed by the addition of a substanceor material to the surface of the media such as, for example, a smallbead of adhesive or polymer. In general, the distance of the firstseparation and the second separation can be defined by the height of thebosses located therein.

FIGS. 9A-9D illustrate an example embodiment of a media pack 20, made inaccordance with principles of this disclosure. The media pack 20 is acoiled construction 22. The media pack 20 can also be referred to as arolled construction or as a wound construction. The coiled construction22 can include alternating layers of a first media sheet 24 and a secondmedia sheet 26 coiled together to form the media pack 20. The media pack20 includes a first flow face 28 and a second, opposite flow face 30. Ingeneral, fluid, such as air or liquid, to be filtered can enter one ofthe first flow face 28 or the second flow face 30, pass through at leastone of the first media sheet 24 or the second media sheet 26 in orderprovide for filtration, and then exit through the other one of the firstflow face 28 or the second flow face 30. In the case of the media pack20, the first flow face 28 includes a first separation or gap 29, andthe second flow face 30 includes a second separation or gap 31. Thefirst separation or gap 29 and the second separation or gap 31 refer tothe separation between the first media sheet 24 and the second mediasheet 26 that permits fluid to flow therethrough. In general, the flowthrough the media pack 20 can be said to be straight-through flow oraxial flow, because the fluid, such as air or liquid to be filtered,flows generally along a straight line when flowing from the first flowface 28 to second flow face 30 (or vise versa), without having to turn acorner, such as a 90 degree turn, except to flow through one or more ofthe first media sheet 24 or the second media sheet 26. Alternatively,the flow can be said to be straight-through because the direction offlow when the fluid enters the media pack 20 can be provided in a samedirection as the fluid exiting the media pack 20. In this example, thefirst flow face 28 and second flow face 30 are generally flat andparallel to each other. There can be variations, including, conicalfaces or slanted faces, and the faces can be parallel or non-parallel.

In order to force fluid flowing from either the first flow face 28 orthe second flow face 30 to the other of the first flow face 28 or thesecond flow face 30 to flow through the first media sheet 24 or thesecond media sheet 26, the gap 29 or the gap 31 can be closed at somepoint thereby forcing the fluid through the media so that the fluidflows from the gap 29 to the gap 31 or from the gap 31 to the gap 29. Byway of example, fluid flowing into the media pack 20 via the first flowface 28 may enter through the gap 29 because the gap 31 is closed as aresult of the adhesive 35. The fluid is then not permitted to leave themedia pack 20 via the gap 29 because at some point gap 29 is closed bythe adhesive 33. As a result, the fluid flows through the media and thenis available to flow via the gap 31 and out the second flow face 30.Thus, the adhesive 33 can provide closure of the gap 29 and the adhesive35 can provide closure of the gap 31. In order to maximize the length ofgap of each gap, the adhesive 35 can be provided proximate or at thefirst flow face 28, and the adhesive 33 can be provided proximate or atthe second flow face 30. It should be appreciated that the length ofeach gap can be adjusted, such as shortened, by providing the adhesivefurther away from the flow face, if desired.

FIG. 10 shows a schematic illustration of an exemplary method of makingthe media pack 20 of FIGS. 9A-9D at reference number 10. In the methodshown, the first media sheet 24 is unrolled from a roll 24′, and thesecond media sheet 26 is unrolled from a roll 26′. The first media sheet24 and the second media sheet 26 are adhered together at a firstlocation 32 thereby forming a single facer media 25. In the exampleembodiment illustrated, the first location 32 can be adjacent orproximate a first edge 34 of the first media sheet 24 and the secondmedia sheet 26.

After the first media sheet 24 and second media sheet 26 are adheredtogether at the first location 32 as a result of applying adhesive 33 atthe first location 32, the resulting combination, which can be referredto as the single facer media 25, can be wound or coiled or stacked toform a media pack. In the case of stacking, the single facer media 25 iscut to form sheets that are stacked on top of each other. Prior towinding or coiling or stacking, adhesive 35 can be applied at a secondlocation 36 for adhering the secured media sheets 24, 26. The secondlocation 36 can be adjacent or proximate to a second edge 38 of thefirst media sheet 24 and second media sheet 26. The second location 36can be provided at an opposite side of the first media sheet 24 andsecond media sheet 26 from the first location 32.

Adhering the first media sheet 24 and second media sheet 26 can includea variety of techniques. For example, the steps of adhering can includeapplying an adhesive 33 at the first location 32 and applying anadhesive 35 at the second location 36. The adhesive 33 and/or theadhesive 35 can be applied as a continuous bead or a plurality ofdiscontinuous beads, and can be provided as a hot melt adhesive or as areactive cure adhesive. In general, it may be desirable for theadhesives 33 and 35 to have an open time sufficient to allow the firstmedia sheet 24 and the second media sheet 26 to slide relative to eachother during formation of the media pack in order to adjust ordistribute internal stresses that may occur as a result of, for example,forming the media pack. An “open time” refers to a time afterapplication of the adhesive where the adhesive is not cured and themedia sheets can move relative to each other. In the case of winding orcoiling the single facer media 25, it may be beneficial to allow thefirst media sheet 24 and the second media sheet 26 to slide relative toeach other prior to cure of the adhesive 33 and/or 35. Other techniquesfor forming the media pack are possible. For example, rather thanwinding or coiling, the media pack can be formed by stacking a pluralityof discrete sheets of the single facer media 25. Furthermore,alternative techniques to applying adhesive for securing the first mediasheet 24 to the second media sheet 26 for closing the gaps 29 and 31 canbe provided.

The method 10 includes an embossing or dimpling station 12. At theembossing or dimpling station 12, either the first media sheet 24 or thesecond media sheet 26, or both of the first media sheet 24 and thesecond media sheet 26 are processed for the formation of bosses,projections, or dimples 14. In the method 10, it is the first mediasheet 24 that is treated by the embossing station 12 to form bosses 14.In particular, the embossing station 12 includes a first roller 16 and asecond roller 18 that form the bosses 14. The bosses 14 include firstbosses 14′ responsible for maintaining the first separation or gap 29,and second bosses 14″ responsible for maintaining the second separationor gap 31. When bosses 14 are provided on both the first media sheet 24and the second media sheet 26, an additional set of first roller 16 andsecond roller 18 can be provided for embossing the second media sheet26. It should be understood that the reference to bosses 14 includesdeformation of the media, and the bosses 14 can also be referred to asprojections or dimples or bumps. In general, the terms bosses,projections, dimples, and bumps should be understood to beinterchangeable in the context of this disclosure and that they relateto describing the result of deforming the media.

In accordance with the principles of this disclosure, a variety ofimplementations for the first media sheet 24 and second media sheet 26are possible. The media sheets 24 and 26 can be made from a variety ofmaterials. For example, the media sheets 24, 26, as with all the mediasheets described herein, can comprise cellulose media, synthetic media,or a blend of cellulose and synthetic. The media sheets 24, 26 may alsoinclude an application of nanofibers to at least one of the sides of oneof the media sheet. For example, each of the media sheets 24 and 26 mayinclude an application of nanofibers to both sides of one of the mediasheets or both of the media sheets.

FIGS. 1 and 2 illustrate a first embodiment of one of the first andsecond sheets 24, 26 shown herein at reference number 40. The mediasheet 40 includes a first side 42 and an opposite second side 44. Themedia sheet 40 includes a plurality of first bosses 46 extending fromthe media sheet first side 42 in a first direction 43 away from thefirst side 42, and a plurality of second bosses 48 extending from themedia sheet second side 44 in a second direction 45 away from the secondside 44. In the case of the media sheet 40, the first direction 43 andthe second direction 45 are opposite each other.

In this embodiment, the bosses 46 project away from a remaining portionof the first side 42 at a distance greater than the distance that thebosses 48 project away from a remaining portion of the second side 44.The bosses 46 are responsible for providing the first separation or gap29, and the bosses 48 are responsible for providing the secondseparation or gap 31. It should be appreciated that the distance thebosses 46 and 48 extend away from the first side 42 and the second side44, respectively, can be the same or different and can be adjusted toprovide the desired first separation 29 and the desired secondseparation 31. In the context of a media pack, where the firstseparation (the first gap) is open to the inlet flow face, it is oftendesirable for the first gap to be relatively larger than the second gapto accommodate greater loading of material to be filtered from thefluid. In general, as the first gap fills up with particulate material,there is an associated pressure drop through the media pack. Byproviding a greater volume in the first separation, it is possible toaccommodate a greater loading of particulate during filtration beforeexperiencing an associated pressure drop. The second separation whichcorresponds to the outlet flow face can be relatively smaller because itaccommodates the outlet flow of fluid and not the accumulation ofparticulate material. Of course, this can be reversed so that the firstseparation which receives the inlet flow of fluid is smaller than thesecond separation which receives the outlet flow of cleaned fluid. Inaddition, the first separation and the second separation can have aboutthe same size. The density of the first bosses 46 and the second 48 canbe provided to accommodate internal pressures within in the media packas a result of fluid flowing therethrough. The density of the bossesrefers to the number of bosses per unit area. In general, when the firstseparation is open to the inlet flow face, relatively fewer first bosses46 are needed to maintain the first separation. The reason for this isthat the fluid flowing into the inlet flow face fills the firstseparation and helps keep it open. In contrast, the second separationwhich is open to the outlet flow face tends to require a greater densityof bosses 48 in order to resist media deformation that would tend tocause a collapse of the second separation as a result of fluid flowingthrough the media pack. Accordingly, the size of the bosses 46 and 48can be adjusted to accommodate the desired first separation 29 andsecond separation 31, respectively, and the density of the bosses 46 and48 can be provided to maintain the first separation 29 and the secondseparation 31, respectively, during filtration.

In FIG. 1, in this illustrated embodiment, there can be at least aboutthree times more of the bosses 48 than there are of the bosses 46 in agiven area. There can be at least four times as many of one type ofbosses than the other, and there may be as many as five times as many orsix times as many bosses of one type than the other type. Many differentvariations can be provided. In FIG. 1, in this example embodiment, thebosses 46 are in alignment with each other while the bosses 48 are inalignment with each other. The bosses 46 are staggered relative to thebosses 48. Many different variations can be made. The portion of themedia sheet 40 that does not include the bosses 46 or the bosses 48 canbe referred to as the “remaining portion” and can be characterized asnon-fluted and/or non-corrugated, if desired.

In accordance with the first embodiment, the media sheet 40 can be usedwith a second media sheet for the media pack. The second media sheet canbe a flat media sheet. In general, a flat media sheet refers to a mediasheet without bosses thereon. An exemplary second media sheet is shownat reference number 26 (FIGS. 9B, 9D, and 10). Alternatively, the secondmedia sheet can include bosses to help form or maintain the firstseparation or the second separation. Furthermore, the second media sheetcan be provided as non-fluted or non-corrugated, and the media sheet 40can be provided as non-fluted or non-corrugated.

Now referring to FIGS. 3-6, a second embodiment is shown. FIGS. 3 and 4illustrate another example embodiment of a media sheet 50 that can beused as the first media sheet 24 or the second media sheet 26 for themedia pack 20. The media sheet 50 has a first side 52 and an oppositesecond side 54. Projecting from the first side 52 are a plurality offirst bosses 56. In this embodiment, the bosses 56 project from aremaining portion of the first side 52 in a first direction 53, whilethe second side 54 includes no bosses extending from a remaining portionof the second side 54 in a second direction 55. In FIGS. 3 and 4, thebosses 56 are shown to be relatively evenly spaced with respect to eachother. Many variations can be made. The reference to “a remainingportion” refers to the part of the first side or the second side that isnot deformed by embossing. For example, the first bosses 56 includeportions that form the first side 52 and the second side 54, but thoseportions are not part of the “remaining portion” of either the firstside 52 or the second side 54. In other words, the “remaining portion”is the portion separate from the bosses. The “remaining portion” can beadditionally characterized as non-fluted and/or non-corrugated, ifdesired.

FIGS. 5 and 6 illustrate another example of a media sheet 60 that can beused as either the first or second media sheet 24, 26 in the media pack20. The media sheet 60 includes a first side 62 and an opposite secondside 64. Extending from a remaining portion of the first side 62 are aplurality of first bosses 66 in a first direction 63. The second side 64is free of any bosses extending from a remaining portion of the secondside 64 in a second direction 65. Comparing the embodiments of mediasheet 50 of FIG. 3 and media sheet 60 of FIG. 5, it can be seen howthere is a smaller density of bosses 66 for media sheet 60 compared tobosses 56 for media sheet 50. In this embodiment, the bosses 66 areevenly spaced relative to each other. Many different variations can bemade. In addition, the portion of the media sheet 60 that does notinclude the bosses 66 can be characterized as the “remaining portion,”and can be provided as non-fluted and/or non-corrugated, if desired.

In the second embodiment, the media sheet 50 and the media sheet 60 canbe assembled together to form a single facer media and, subsequently, amedia pack. In general, when the media sheet 50 and the media sheet 60are arranged together, the first bosses 66 can be responsible forproviding the first separation, and the first bosses 56 can beresponsible for providing the second separation. In this situation, thefirst separation can be provided as the separation open to the inletflow face and the second separation can be provided as a separation opento the outlet flow face so that the first separation has a greatervolume than the second separation in a media pack. Of course, thisarrangement can be reversed so that second separation can be provided asopen to the inlet flow face and the first separation is open to theoutlet flow face.

As discussed previously, the height of the bosses 46, 48, 56, and 66 canbe selected to provide the desired media separations, and the density ofthe bosses 46, 48, 56 and 66 can be selected to accommodate thepressures on the media during filtration to thereby maintain the desiredseparations between media. Furthermore, the shapes of the bosses 46, 48,56, and 66 can be selected as desired. In general, the shape may beselected to accommodate the deformation of the media without tearing orripping the media. For example, sharp edges might tend to result intears in the media as a result of the embossment technique. Accordingly,a preferred boss shape may be one that avoids sharp edges where tears inthe media may occur. An exemplary shape that accomplishes this is aconical shape with a curved or domed top as shown in FIGS. 1-6.

Now referring to FIG. 12, where an exemplary domed top boss orprojection or dimple or bump is shown at reference number 90 extendingfrom a media sheet 92. When embossing media, strain is induced due tothe media stretching during the deformation process. If the strainexceeds the strain limit of the media, the media will tear instead ofstretch. Tearing the media during the embossing process creates anundesirable leak path for unfiltered air to move from the dirty side tothe clean side of the filter without filtration thereof. Accordingly, itis desirable to avoid tearing the media during the embossing process.

To prevent the media from tearing during the embossment process, theprocess can be provided so that it does not strain the media past thestrain limit. This can be accomplished by increasing the surface areaover which an embossment is formed relative to the height of theembossment. For small surface area embossments, shorter embossmentheights may be achieved. For larger surface area embossments, tallerembossment heights may be achieved without increasing the media strainto an unacceptable level during the embossment process. Typical level ofacceptable strain is less than 12% for cellulosic media not containingsynthetic fiber. Media containing synthetic fiber can typically toleratestrain in excess of 12% without tearing. The acceptable level of straindepends on media properties and environmental conditions at the time ofprocessing. The strain limit can be increased, for example, by applyingheat and moisture to the media during the embossment process.

The strain achieved during the embossment process can be calculated asthe ratio of the difference between the length along the embossmentalong the length of the base of the embossment (under the length alongthe embodiment) and divided by the length of the base of the embossment.This strain may be expressed by the following equation.Strain=(s−d)/dThe letter “d” refers to the length of the base of the embossment, andthe letter “s” refers to the length along the embossment from the endpoints of the length of the base of the embossment. This is shown inFIG. 12. Increasing “d” allows for a greater value of “s” whilemaintaining the same strain. Greater “s” values typically allow taller(greater “h”) bosses, projections, bumps, or dimples to be formed. Theletter “h” refers to the dimple height. In the case of a dimple having acircular base, the base can be characterized as having a radiusindicated by the letter “r” which is one half of the dimple length orwidth (d).

The dimple length (or width) and height can be selected as desired. Forexample, the dimple height may be selected to provide the upstreamand/or downstream separation between adjacent media. The upstream anddownstream separations can be provided as about the same or different.When the upstream and downstream separations are about the same (adifference of less than 10%), then the media pack can be said to exhibitvolume symmetry. When the upstream and downstream separations aredifferent by 10% or greater, the media pack can be said to exhibitvolume asymmetry. An exemplary volume asymmetry occurs when one sideexhibits a separation that is about 110% or greater compared to theseparation of the other side. Exemplary ranges include about 110% toabout 200%, and about 130% to about 170%. In many applications, theupstream separation can be provided as greater than the downstreamseparation. One reason for this is that the upstream side of the mediapack tends to collect the particulates that are being filtered out ofthe fluid, and it may be desirable to provide the upstream side withgreater volume to handle the particulate loading. The life of the mediapack can be extended as a result of creating greater upstreamseparation. Accordingly, it may be desirable to provide a volumeasymmetry wherein the upstream separation is greater than the downstreamseparation.

The upstream separation between adjacent media and the downstreamseparation between adjacent media can be characterized by the dimpleheight (h). Because the dimples help provide separation between adjacentsheets of media, the dimple height can be used to identify the mediaseparation. Depending on whether the dimple being characterized islocated on the upstream side or the downstream side, the mediaseparation can be characterized as an upstream separation or adownstream separation. The following exemplary ranges of dimple heightcan be used to identify a separation between adjacent sheets of media.It should be understood, however, that the media has a tendency todeflect when provided under pressure. As a result of deflection of themedia, the actual media separation during use may be somewhat differentthan the dimple height provided between adjacent media. The fluid flowtends to separate the media on the upstream side, and tends to push themedia together on the downstream side. Depending on how well the mediais supported by the dimples, the media separation during use might beless than the dimple height on the downstream side. In general, thedimples can be provided having a height and a dimple density or dimpleseparation that maintains the desired level of separation betweenadjacent media. By way of example, the dimples can be provided having aheight of about 0.01 inch to about 0.25 inch and can be provided havinga height of about 0.05 inch to about 0.2 inch. In general, the densityof the dimples can be provided as about 4,500 dimples/in² to about 0.25dimples/in². In addition, the media can be characterized as exhibiting adimple separation. In general, the separation refers to the distancebetween closest dimples. In general, the dimple separation and dimpledensity can be selected to provide sufficient support to provide desiredseparation between adjacent media sheets and resist deflection of themedia. By way of example, a dimple separation can be provided from about0.03 inch to about 4.0 inch. It should additionally be appreciated thaton the upstream side, it may be possible to provide separation betweenadjacent sheets without utilizing dimples. Because the pressure of thefluid tends to force the upstream side open, it may be possible toforego the presence of dimples on the upstream side. It is generallyexpected that the dimples on the downstream side would be advantageousto resist the pressure of the fluid in order to hold the adjacent sheetsseparate from each other and reduced masking.

As discussed above, the upstream side can be provided without dimples.However, dimples can be advantageous to help maintain separation on theupstream side. The dimples on the upstream side, when present, can beprovided having a dimple height of about 0.05 inch to about 0.25 inch,or about 0.1 inch to about 0.2 inch. The dimples on the upstream sidecan have a dimple density of about 36 dimples/in² to about 0.25dimples/in², about 9 dimples/in² to about 0.32 dimples/in², or about 2.3dimples/in² to about 0.4 dimples/in². Furthermore, the upstream side canprovide a dimple separation of about 0.5 inch to about 4.0 inches, adimple separation of about 1.0 inch to about 3.5 inches, or a dimpleseparation of about 2.0 inches to about 3.0 inches. In the case of thedownstream side, the dimples help keep the adjacent sheets from touchingeach other except at the location of the dimples. In general, the dimpleheight can be provided as about 0.01 inch to about 0.2 inch or about0.05 inch to about 0.15 inch. The dimple density can be provided asabout 4,500 dimples/in² to about 4 dimples/in², or about 3,600dimples/in² to about 6.25 dimples/in². Furthermore, the dimpleseparation on the downstream side can be provided as about 0.03 inch toabout 1.0 inch or about 0.05 inch to about 0.8 inch.

The bosses 46, 48, 56, 66 can have a perimeter area of at least 0.2in-2, for example, 0.1 in sq.-0.26 in sq. The bosses can be separatedfrom each other by a distance of at least 0.15 in, for example, about0.2 in to about 1.0 in. The bosses 46, 48, 56, 66 can be populated witha boss density of at least 0.5 per square inch; in many examples, atleast 1 per square inch, for example, about 5-30, or about 25 per squarein. The bosses 46, 48, 56, 58 can have a conical sidewall. In otherembodiments, the bosses 46, 48, 56, 58 can be domed in shape.

In FIG. 7, the first media sheet 40 is shown adhered to a flat sheet 70wherein the flat sheet 70 is free of bosses. Of course, it should beunderstood that the flat sheet 70 can be replaced with a sheet havingbosses extending from one side or both sides such as media sheet 40, 50,and 60 in order to help maintain the first separation 29 and the secondseparation 31. The construction shown can be provided as a result ofwinding or coiling a single facer media 25, or as a result of stacking asingle facer media 25. The construction can be considered a coiled mediapack or a stacked media pack depending upon whether it was formed as aresult of winding or stacking, respectively.

As seen in FIG. 7, several layers of media are shown. In FIG. 7, themedia sheet 40 includes first bosses 46 extending from the first mediafirst side 42 toward the flat sheet 70, which is a second media sheet 72in this embodiment. This provides a first separation 29 between thefirst media sheet 40 first side 42 and the second media sheet 72 secondside 74. The bosses 48 extending from the second side 44 of the firstmedia sheet 40 extend in a direction opposite the bosses 46 and providea second separation 31 between the first media sheet second side 44 andthe second media sheet first side 76.

As described above, the first media sheet 40 and the second media sheet70 are adhered together at first location 32 to form the firstseparation open at the second flow face 30, while the first media sheet40 and the second media sheet 70 are adhered together at the secondlocation 36 to form the second separation open at the first flow face28. When formed into a media pack, the media pack is closed to thepassage to unfiltered fluid therethrough from the first face 28 to thesecond flow face 30 or from the second flow face 30 to the first flowface 28 without filtering the passage through the media, being mediasheet 40 or flat sheet 70, in the illustrated embodiment of FIGS. 9B and9D.

FIG. 8 illustrates another example embodiment of media used in the mediapack. In this embodiment, the media sheet 50 is secured to the mediasheet 60, and then coiled or stacked into a media pack. The media sheet50 includes first bosses 56 extending from the first side 52 toward thesecond media sheet 60 to provide a first separation 29 between the firstside 52 of the media sheet 50 and the second side 64 of the media sheet60. A plurality of first bosses 66 extend from the first side 62 of themedia sheet 60 in a same direction as the bosses 56 to provide a secondseparation 31 between the first side 62 of the second media sheet 60 andthe second side 54 of the first media sheet 50. When the media sheet 50and 60 are adhered together at the described first location 32 andsecond location 36, the first and second flow face 28, 30 are formed.

In FIG. 11, the media sheet 40 used to form both the first media sheetand the second media sheet. The media sheet 40 is secured to a flippedover version of itself in FIG. 11 and then coiled or stacked to form amedia pack. In this embodiment, both of the media sheets 40 forming thefirst media sheet 24 and second media sheet 26 include protrusions,dimples, or bosses extending from both the first side 42 and second side44 to provide separations 29 and 31.

From a review of FIGS. 7, 8, and 11, it can be appreciated how thebosses 46, 48, 56, 66 in each of these embodiments are staggeredrelative to each other to help maintain the first separation 29 and thesecond separation 31.

Coiling of the media, rather than pleating, provides strength againstmedia deformation under fluid flow. This strength can be referred to ashoop strength, and allows fewer bosses to be used on the face of themedia, for instance, as compared to pleated media packs. In one example,deflection of a coiled element with bosses is reduced to 50% of the flatsheet deflection with the same boss arrangement. Reducing the number ofbosses in the media pack, while maintaining the overall resistance todeflection, is beneficial since where each boss touches an adjacentmedia surface, masking occurs—reducing the potential filtration areaavailable to dirty air.

The media packs can be arranged in any desired configuration. Exemplaryconfigurations include coiled and stacked filter configurations. Coiledconfigurations are often arranged as a result of coiling or rolling asingle facer media formed of the first media sheet and the second mediasheet. Exemplary cross sectional shapes of the resulting coiledconfiguration include circular, racetrack, round, obround, and oval. Ingeneral, racetrack shaped refers to two opposite curved ends joined bytwo opposite straight sides. A round cross sectional shape may bepreferable provided as a coiled configuration because it provides for abalanced distribution of forces across the media pack therebymaintaining the first and second separations. In contrast, a racetrackshaped coiled construction may be formed by winding into a racetrackshape or winding into a circular shape and then deforming to form aracetrack shape. An exemplary technique forming a racetrack shaped mediapack can be a coiled and crushing technique such as that disclosed inU.S. Pat. No. 8,226,786. In the case of a racetrack shape, the forceswithin the media pack may differ across the media pack thereby resultingin certain parts of the first separation or the second separation ashaving a different value than other parts of the first separation or thesecond separation, respectively. As a result, the separation between thesheets of media may vary and the fluid flow through the media pack maybe effected. Stacked configurations are often arranged as a result ofalternately stacking a single facer media formed of the first mediasheet and the second media sheet. Exemplary cross sectional shapes ofthe resulting stacked configuration include parallelograms such assquare, rectangular, and rhombus. Alternatives are possible includingvarious trapezoid shapes and kite shapes depending, for example, on howthe length of each single facer sheet is selected. Similarities in mediapack cross sectional shapes can be observed in the context of thepreviously mentioned fluted or z-filtration media described. Whilefluted filtration media typically includes an alternating single facermedia formed from a fluted sheet and a facing sheet, the filtrationmedia pack described herein need not contain a fluted sheet. That is,both sheets in the described filtration media can be provided asnon-corrugated sheets or non-fluted sheets.

The filtration media pack includes an inlet flow face where fluid to befiltered enters the media pack, and an outlet flow face where filteredfluid exits the media pack. The inlet flow face and the outlet flow facecan be provided on opposite sides on the media pack. In addition, theinlet flow face and the outlet flow face can be planer and parallel, butcan also be provided as non-planer and/or non-parallel.

The bosses or protrusions can be configured to provide beneficialproperties to the resulting media pack. As discussed previously, firstbosses on one side of a media sheet (either extending from the mediasheet or an adjacent media sheet) help define a first separation or gapbetween adjacent media sheets, and the bosses on the other side of themedia sheet (either extending from the media sheet or an adjacent mediasheet) help define a second separation or gap between adjacent mediasheets. When the first bosses and the second bosses have heights thatare equal or close to equal, the volume occupied by the first separationor gap and the volume occupied by the second volume or gap can beconsidered relatively equal, and the media pack can be considered ashaving volume symmetry. When the difference in volume is greater thatabout 10%, the media pack can be considered as having volume asymmetry.This difference between upstream and downstream volumes can becharacterized as media volume asymmetry. Media volume asymmetry occurswhen one side of a media pack (either the upstream side or thedownstream side) has a different volume compared the other side of themedia pleat pack. Such asymmetry may be created by the manner in whichthe bosses are constructed. For example, bosses or protrusions having afirst height can result in a first separation or gap, and second set ofbosses or protrusions can provide a second separation or gap. The firstgap and the second gap can be the same or they can be different. Thefirst gap and the second gap are different, and the difference isgreater than about 10%, then the difference can be referred to as volumeasymmetry. The difference between the first gap and the second gap isabout 10% or less, than the difference may not actually be a result ofvolume asymmetry but rather differences in the bosses used to form themedia or differences resulting from pressures of the fluid against themedia during filtration.

Media volume asymmetry is beneficial for various reasons, includingimproved fluid flow and improved loading performance. In someimplementations, media will demonstrate a media volume asymmetry ofgreater than 15%, greater than 20%, or greater than 50%.

FIGS. 1 and 2 shows dimensions of example protrusions 46 and 48 on themedia. The protrusions 46 and 48 are shown with example length d, heighth, and width w. The height of the projection can refer to the distancebetween the top of the projection and the tops of the flat portion offiltration media. The projection can be provided having a symmetric orasymmetric shape. When symmetric, the values of d and w can be the sameor about the same. In the case of a dome-shape, the shape is expected tobe relatively symmetrical and the width w and the length d can be thesame or about the same. These dimensions of d and w are expected to bedifferent when the shape is asymmetrical such as an oblong projection ordimple.

Filtration Media Generally

The filtration media can be provided as a relatively flexible media,including a non-woven fibrous material containing cellulose fibers,synthetic fibers, glass fibers, or combinations thereof, often includinga resin therein, and sometimes treated with additional materials. Anexample filtration media can be characterized as a cellulosic filtrationmedia that can tolerate about up to twelve percent (12%) strain withouttearing when warm, but which will rupture at lower percent strain whendry and cold (as low as 3% with some media). The filtration media can becorrugated, embossed, scored or creased without unacceptable mediadamage. In addition, the filtration media is desirably of a nature suchthat it will maintain its boss structure during use. While somefiltration media is available that can tolerate greater than abouttwelve percent (12%) strain, and such media can be used according to theinvention, that type of media is typically more expensive because of theincorporation therein of synthetic fibers.

The filtration media can be provided with a fine fiber material on oneor both sides thereof, for example, in accord with U.S. Pat. Nos.6,955,775, 6,673,136, and 7,270,693, incorporated herein by reference intheir entirety. In general, fine fiber can be referred to as polymerfine fiber (microfiber and nanofiber) and can be provided on the mediato improve filtration performance. As a result of the presence of finefiber on the media, it can be possible to provide media having a reducedweight or thickness while obtaining desired filtration properties.Accordingly, the presence of fine fiber on media can provide enhancedfiltration properties, provide for the use of thinner media, or both.Fiber characterized as fine fiber can have a diameter of about 0.001micron to about 10 microns, about 0.005 micron to about 5 microns, orabout 0.01 micron to about 0.5 micron. Exemplary materials that can beused to form the fine fibers include polyvinylidene chloride, polyvinylalcohol polymers, polyurethane, and co-polymers comprising variousnylons such as nylon 6, nylon 4,6, nylon 6,6, nylon 6,10, andco-polymers thereof, polyvinyl chloride, PVDC, polystyrene,polyacrylonitrile, PMMA, PVDF, polyamides, and mixtures thereof.

Filter Elements

The following filter elements are provided as examples constructed inaccordance with the present disclosure, and are not intended to beinclusive of all element designs made in accordance with the teachingsherein. One of skill in the art will appreciate that various alternativeelements can be constructed while still within the scope of thedisclosure and claims. The filter elements can be utilized in varioushousing arrangements, and the filter elements can be replaced or cleanedor refurbished periodically, as desired. In the case of air filtration,the housing can be provided as part of an air cleaner for various aircleaning or processing applications including engine air intake, turbineintake, dust collection, and heating and air conditioning. In the caseof liquid filtration, the housing can be part of a liquid cleaner forcleaning or processing, for example, water, oil, fuel, and hydraulicfluid.

Now referring to FIGS. 13-24, filter elements are described that includea filtration media pack. The filtration media pack can be provided basedupon the media pack characterizations described herein, and based uponthe exemplary media definitions. One will understand how the filterelements shown in FIGS. 13-24 can accept the media as characterizedherein. For example, the media can be provided as coiled or stacked.Certain filter elements characterized as air filtration elements becausethey can be used to filter air, and other filters can be characterizedas liquid filters because they filter liquids.

The filtration media pack can be provided as part of a filter elementcontaining a radial seal as described in, for example, U.S. Pat. No.6,350,291, US Patent Application No. US 2005/0166561, and InternationalPublication No. WO 2007/056589, the disclosures of which areincorporated herein by reference. For example, referring to FIG. 13, thefilter element 300 includes filtration media pack 301 that can beprovided as a wound media pack 302 of single facer media, and caninclude a first face 304 and a second face 306. A frame 308 can beprovided on a first end of the media pack 310, and can extend beyond thefirst face 304. Furthermore, the frame 308 can include a step orreduction in circumference 312 and a support 314 that extends beyond thefirst face 304. A seal member 316 can be provided on the support 314.When the filter element 301 is introduced within the housing 320, theseal member 316 engages the housing sealing surface 322 to provide aseal so that unfiltered air does not bypass the filtration media pack300. The seal member 316 can be characterized as a radial seal becausethe seal member 316 includes a seal surface 317 that engages the housingsealing surface 322 in a radial direction to provide sealing. Inaddition, the frame 308 can include a media pack cross brace or supportstructure 324 that helps support the frame 308 and helps reducetelescoping of the air filtration media pack 300. An access cover 324can be provided for enclosing the filter element 300 within the housing320.

The filtration media pack can be provided as part of a filter elementhaving a variation on the radial seal configuration. As shown in FIG.14, the seal 330 can be relied upon for holding the frame 332 to themedia pack 334. As shown in FIG. 14, the frame 332 can be attached tothe media pack 334 by molding the seal 330 to the seal support 338 andthe media pack 334. As shown in FIG. 14, the frame 338 can be providedadjacent to the first face 336 and the seal 330 can be provided so thatit holds the support 332 onto the media pack 334 without the use ofadditional adhesive. The seal 330 can be characterized as an overmoldseal and that it extends along both sides of the seal support 338 andonto the outer surface of the media pack 334 at the first end 340.

The filtration media pack can be provided as part of a filter elementaccording to U.S. Pat. No. 6,235,195, the entire disclosure of which isincorporated herein by reference. Now referring to FIG. 15, the filterelement 350 includes a wound media pack 352 having an obround orracetrack shape, and an axial pinch seal 354 attached near an end of themedia pack and circumscribing the exterior of the media pack. The axialpinch seal 354 is shown provided between the first face 356 and thesecond face 358 of the media pack. The axial pinch seal 354 includes abase portion 360 and a flange portion 362. The base portion 362 can beprovided for attaching to the media pack. The flange portion 362 can bepinched between two surfaces to create a seal. One of the surfaces canbe a surface of the housing that contains the filter element 350. Inaddition, the other structure that pinches the flange 362 can be anaccess cover or another structure provided within the housing that helpsmaintain the seal so that unfiltered air passes through the media packwithout bypassing the media pack. The filter element 350 can include ahandle 364 extending axially from the first face 356. If desired, thehandle can be provided extending axially from the second face 358. Thehandle 364 allows one to pull or remove the filter element 350 from thehousing. The handle 364 can be provided as part of a center boardextending into the media pack and sealed thereto.

Now referring to FIGS. 16-18, a filter element is shown at referencenumber 400. The filter element 400 includes a wound media pack 402, ahandle arrangement 404, and a seal arrangement 406. Details of thisfilter element construction can be found in U.S. Pat. No. 6,348,084, theentire disclosure of which is incorporated herein by reference. Thepreviously described single facer media can be used to prepare the mediapack 402 of the filter element 400.

The handle arrangement 404 includes a center board 408, handles 410, anda hook construction 412. The single facer media can be wound around thecenter board 408 so that the handles 410 extend axially from a firstface 414 of the media pack 402. The hook arrangement 412 can extend fromthe second face 416 of the media pack 402. The handles 410 allow anoperator to remove the filter element 400 from a housing. The hookconstruction 412 provides for attachment to a cross brace or supportstructure 420. The hook construction 412 includes hook members 422 and424 that engage the cross brace or support structure 420. The crossbrace or support structure 420 can be provided as part of a seal supportstructure 320 (FIG. 13) that extends from the second face 416 andincludes a seal support member 314. A seal member 434 (similar to sealmember 316 in FIG. 13) can be provided on the seal support member toprovide a seal between the filter element 400 and a housing. The seal434 can be characterized as a radial seal when the seal is intended toprovide sealing as a result of contact of a radially facing seal surface436 and a housing seal surface.

The filtration media pack can be provided as part of a gas turbinesystem as shown in U.S. Pat. No. 6,348,085, the entire disclosure ofwhich is incorporated herein by reference. An exemplary gas turbinefiltration element is shown at reference number 450 in FIG. 19. Thefilter element 450 can include a primary filter element 452 and asecondary filter element 454. The secondary filter element 454 can bereferred to as a safety filter element. The primary of main filterelement 452 can be provided as an filtration media pack as previouslydescribed in this application. The filtration media pack can be providedas a result of winding a single facer media or as a result of stacking asingle facer media. The primary filter element 452 and the secondaryfilter element 454 can be secured within a sleeve member 460. The sleevemember 460 can include a flange 462 that includes a seal 464. Wheninstalled, the element 450 can be provided so that the flange 462 andseal 464 are provided adjacent a support 466 and held in place by aclamp 200 so that the seal 464 provides a sufficient seal so thatunfiltered air does not bypass the filter element 450.

The filtration media pack can be provided as part of a filter element asdescribed in U.S. Pat. No. 6,610,126, the entire disclosure of which isincorporated herein by reference. Now referring to FIG. 20, the filterelement 500 includes a filtration media pack 502, a radial sealarrangement 504, and a dust seal or secondary seal arrangement 506. Thefilter element 500 can be provided within an air cleaner housing 510 andcan include, downstream of the filter element 500, a safety or secondaryfilter element 512. Furthermore, an access cover 514 can be provided forenclosing the housing 510. The housing 510 and the access cover 514 canpinch the dust seal 506 so that the dust seal 506 can be characterizedas a pinch seal.

The filtration media pack can be provided as a stacked media packarrangement according to International Publication No. WO 2006/076479and International Publication No. WO 2006/076456, the disclosures ofwhich are incorporated herein by reference. Now referring to FIG. 21, afilter element is shown at reference number 600 that includes a blockedstacked, media pack 602. The blocked stacked media pack 602 can becharacterized as a rectangular or right (normal) parallelogram mediapack. To seal the opposite ends of the media pack 602 are positionedside panels 604 and 606. The side panels 604 and 606 seal the lead endand tail end of each stacked, media. The media pack 602 has oppositeflow faces 610 and 612. Fluid such as air flows into one of the flowfaces 610 and 612 and out the other of the flow faces 610 and 612. It ispointed out that no flow path between faces 610 and 612 is provided thatdoes not also require the air to pass through media of the media pack602 and thus to be filtered. A peripheral, perimeter, housing seal ring614 is positioned in the air filter element 600. The particular sealring 614 depicted is an axial pinch seal ring. If desired, a protectivesheath or panel can be provided over the media pack surfaces 626 and622.

The filtration media pack can be provided as a stacked media packarrangement in a configuration according to International PublicationNo. WO 2007/133635, the entire disclosure of which is incorporatedherein by reference. Now referring to FIG. 22, a filter element is shownat reference number 650. The filter element 650 includes a stacked mediaarrangement 652 having a first, in this instance, inlet face 654, and anopposite second, in this instance, outlet face 656. In addition, thefilter element 650 includes an upper side 660, a lower side 662, andopposite side ends 664 and 666. The stacked media arrangement 652generally comprises one or more stacks of strips. The strips can beprovided in a slanted arrangement. The strips are organized with dimplesextending between the inlet face 654 and the outlet face 656. The filterelement 650 depicted comprises a stacked media pack arrangementcomprising two stacked media pack sections 670 and 672. A seal member680 can be molded to the media pack. In addition, the filter element 650includes an axially extending handle 682. The axially extending handle682 can be provided having a first handle 684 and a second handle 686.The handle 682 can be attached to a center board extending within themedia pack wherein the single facer media can be sealed to the centerboard.

The filtration media pack can be provided as part of a liquid filtrationsystem according to, for example, U.S. Pat. No. 5,895,547, the entiredisclosure of which is incorporated herein by reference. No referring toFIGS. 23 and 24, alternative liquid filtration system as shown atreference numbers 700 and 700A. The filter apparatus 700 is configuredfor use as a liquid filter and is a spin-on filter mounting onto afitting for a circulating fluid system such as a diesel fuel filter forengine oil filter. The filter includes a filter element 702 inside afilter housing 704. The fluid enters an open end 706, flows axiallythrough the filter 702 and then exits the open end 706. The filterelement 702 has an end cap 710 mounted thereon and a gasket 708 forminga seal between the end cap and the annular centered divider segment 724of a mounting element 716. A gasket 718 forms a seal between themounting element 716 and a mounting fixture. The end cap 710 may includea cross braces, with provide additional support at the end of the filterelement 702. A center plug 720 is at the closed end of the housing 721to block the center portion of the filter element 702 and may alsoprovide biasing force between the filter element 702 and the housing 704to aid in positioning the filter elements 702. In the embodiment shown,the filter element 702 includes a center tube 722 around which it isround. However, it can be appreciated that the center tube 722 could bea solid member or the tube may be eliminated so that liquid flows on theperiphery of the filter element and then reverses to flow from theclosed end and through the filter element 702. As shown, fluid entersthe opened end 706 in the annular opening of the mounting member 716between the gasket 718 and the center annular divider segments 724. Theunfiltered fluid then flows on the exterior of the end cap 710 along theinner wall of the housing 704 to the closed end 721 of the housing 704.Fluid then flows through the open ends of the filter element 702,passing through the media and exits the housing open end 106.

Alternatively, FIG. 24 shows an alternate embodiment designated 700A.The filtration system 700A includes a filter element 702A and a housing704. The interior configuration provides a flow pattern wherein liquidflows from the open end 706 axially through the filter element 702A tothe closed end 721 of the housing 704 and then upward through the centertube 722 exiting the open end 706 on the interior of the center dividersegment 724 through the center outlet 714. The filtration system 700Aincludes the mounting member 716 and the gasket 718 forming a sealbetween the mounting member 716 and a fitting. The filter apparatus 700Adoes not require an end cap proximate the open end as flows directlyenters the filter element 702A proximate the open end 706. A gasket 708Ainserts intermediate the center tube 722 which has an extension 723extending upward therefrom that engages the center divider segments 724.A seal 732 can be provided between the filter element 702A and thehousing 704 to prevent fluid from by-passing the filter element 702A.The liquid flows in the direction indicated by the arrows.

It should be appreciated that, in view of exemplary FIGS. 13-24, thatthe filtration media pack can be provided in various configurations toform filter elements that can then be used in various housingarrangements to provide enhanced performance.

Observations

In this summary, some selective, summary characterizations of teachingsherein are provided. Among what is taught are:

-   1. A filter media pack comprising:    -   (a) a media construction comprising alternating first media        sheet and second media sheet secured together and forming a        first flow face and a second flow face, wherein each of the        first media sheet and the second media sheet includes a first        side and a second side;        -   (i) the first media sheet including a plurality of first            bosses extending from the first media sheet first side            toward the second media sheet to provide a first separation            between the first media sheet first side and the second            media sheet second side;        -   (ii) the second media sheet including a plurality of second            bosses extending from the second media sheet first side in a            same direction as the plurality of first bosses to provide a            second separation between the second media sheet first side            and the first media sheet second side;        -   (iii) the first media sheet and the second media sheet            secured together at a first location to form the first            separation open at the second flow face, and the first media            sheet and the second media sheet secured together at a            second location to form the second separation open at the            first flow face;    -   (b) the media construction being closed to passage of unfiltered        fluid therethrough from the first flow face to the second flow        face or from the second flow face to the first flow face without        filtering passage through the first media sheet or the second        media sheet.-   2. A filter media pack according to characterization 1 wherein:    -   (a) the first media sheet and the second media sheet each        comprise a first edge that forms the first flow face and a        second edge that forms the second, opposite, flow face, the        first location for adhering the first media sheet to the second        media sheet is located proximate the first edge, and the second        location for adhering the first media sheet and the second media        sheet is located the second edge.-   3. A filter media pack according to any one of characterizations 1    and 2 wherein:    -   (a) the first media sheet includes a plurality of third bosses        extending from the first media sheet second side in a direction        opposite the plurality of first bosses to provide the second        separation between the first media sheet second side and the        second media sheet first side.-   4. A filter media pack according to any one of characterization 1-3    wherein:    -   (a) the second media sheet includes a plurality of fourth bosses        extending from the second media sheet second side in a direction        opposite the plurality of first bosses to provide the first        separation between the second media sheet second side and the        first media sheet first side.-   5. A filter media pack according to any one of characterizations 1-4    wherein:    -   (a) the plurality of first bosses extend away from the first        media sheet a distance of at least 0.01 inch.-   6. A filter media pack according to any one of characterizations 1-4    wherein:    -   (a) the plurality of first bosses extend away from the media        sheet a distance of about 0.01 inch to about 0.25 inch, or about        0.05 inch to about 0.2 inch.-   7. A filter media pack according to any one of characterizations 1-6    wherein:    -   (a) the plurality of second bosses extend away from the second        media sheet a distance of at least 0.01 inch.-   8. A filter media pack according to any one of characterizations 1-6    wherein:    -   (a) the plurality of second bosses extend away from the second        media sheet a distance of about least 0.01 inch to about 0.25        inch, or about 0.05 inch to about 0.2 inch.-   9. A filter media pack according to any one of characterizations 1-8    wherein:    -   (a) the plurality of first bosses are separated from each other        by a distance of at least 0.03 inch.-   10. A filter media pack according to any one of characterizations    1-8 wherein:    -   (a) the plurality of first bosses are separated from each other        by a distance of about 0.03 inch to about 4.0 inches.-   11. A filter media pack according to any one of characterizations    1-10 wherein:    -   (a) the plurality of second bosses are separated from each other        by a distance of at least 0.03 inch.-   12. A filter media pack according to any one of characterizations    1-10 wherein:    -   (a) the plurality of second bosses are separated from each other        by a distance of about 0.03 inch to about 4.0 inches.-   13. A filter media pack according to any one of characterizations    1-12 wherein:    -   (a) the plurality of first bosses are provided with a boss        density of at least about 0.25 per square inch.-   14. A filter media pack according to any one of characterizations    1-13 wherein:    -   (a) the plurality of second bosses are provided with a boss        density of at least about 0.25 per square inch.-   15. A filter media pack according to any one of characterizations    1-14 wherein:    -   (a) the media construction exhibits a volume asymmetry where one        side exhibits a separation that is 110% or greater compared to        another side, preferably the separation is 110% to 200%, or 130%        to 170%.-   16. A filter media pack according to any one of characterizations    1-15 wherein:    -   (a) the first location comprises a first glue bead adhering the        first media sheet and second media sheet; and    -   (b) the second location comprises a second glue bead adhering        the first media sheet and second media sheet.-   17. A filter media pack according to any one of characterizations    1-16 wherein:    -   (a) the plurality of first bosses have a conical sidewall.-   18. A filter media pack according to any one of characterizations    1-17 wherein:    -   (a) the plurality of second bosses have a conical sidewall.-   19. A filter media pack according to any one of characterizations    1-18 wherein:    -   (a) the plurality of first bosses have a domed top.-   20. A filter media pack according to any one of characterizations    1-19 wherein:    -   (a) the plurality of second bosses have a domed top.-   21. A filter media pack according any one of characterizations 1-20    wherein:    -   (a) the filter media construction is in a coiled configuration.-   22. A filter media pack according any one of characterizations 1-20    wherein:    -   (a) the filter media construction is in a stacked configuration.-   23. A filter media pack according to any one of characterizations    1-22 wherein:    -   (a) neither of the first media sheet nor the second media sheet        is a fluted or corrugated media sheet.-   24. A filter media pack comprising:    -   (a) a media construction comprising alternating first media        sheet and a second media sheet secured together and forming a        first flow face and a second flow face, wherein each of the        first media sheet and the second media sheet includes a first        side and a second side;        -   (i) the first media sheet including a plurality of first            bosses extending from the first media sheet first side            toward the second media sheet to provide a first separation            between the first media sheet first side and the second            media sheet second side, and a plurality of second bosses            extending from the first media sheet second side in a            direction opposite the plurality of first bosses to provide            a second separation between the first media sheet second            side and the second media sheet first side;        -   (ii) the first media sheet and the second media sheet            secured together at a first location to form the first            separation open at the second flow face, and the first media            sheet and the second media sheet secured together at a            second location to form the second separation open at the            first flow face;    -   (b) the media construction being closed to passage of unfiltered        fluid therethrough from the first flow face to the second flow        face or from the second flow face to the first flow face without        filtering passage through the first media sheet or the second        media sheet.-   25. A filter media pack according to characterization 24 wherein:    -   (a) the first media sheet and the second media sheet each        comprise a first edge that forms the first flow face and a        second edge that forms the second, opposite, flow face, the        first location for adhering the first media sheet to the second        media sheet is located proximate the first edge, and the second        location for adhering the first media sheet and the second media        sheet is located proximate the second edge.-   26. A filter media pack according to any one of characterizations 24    and 25 wherein:    -   (a) the second media sheet includes a plurality of third bosses        extending from the second media sheet first side in a same        direction as the plurality of first bosses to provide the second        separation between the second media sheet first side and the        first media sheet second side.-   27. A filter media pack according to any one of characterization    24-26 wherein:    -   (a) the second media sheet includes a plurality of fourth bosses        extending from the second media sheet second side in an opposite        direction as the plurality of first bosses to provide the first        separation between the second media sheet second side and the        first media sheet first side.-   28. A filter media pack according to any one of characterizations    24-27 wherein:    -   (a) the plurality of first bosses extend away from the first        media sheet a distance of at least 0.01 inch.-   29. A filter media pack according to any one of characterizations    24-27 wherein:    -   (a) the plurality of first bosses extend away from the media        sheet a distance of about 0.01 inch to about 0.25 inch, or about        0.05 inch to about 0.2 inch.-   30. A filter media pack according to any one of characterizations    24-29 wherein:    -   (a) the plurality of second bosses extend away from the second        media sheet a distance of at least 0.01 inch.-   31. A filter media pack according to any one of characterizations    24-29 wherein:    -   (a) the plurality of second bosses extend away from the second        media sheet a distance of about least 0.01 inch to about 0.25        inch, or about 0.05 inch to about 0.2 inch.-   32. A filter media pack according to any one of characterizations    24-31 wherein:    -   (a) the plurality of first bosses are separated from each other        by a distance of at least 0.03 inch.-   33. A filter media pack according to any one of characterizations    24-31 wherein:    -   (a) the plurality of first bosses are separated from each other        by a distance of about 0.03 inch to about 4.0 inches.-   34. A filter media pack according to any one of characterizations    24-33 wherein:    -   (a) the plurality of second bosses are separated from each other        by a distance of at least 0.03 inch.-   35. A filter media pack according to any one of characterizations    24-33 wherein:    -   (a) the plurality of second bosses are separated from each other        by a distance of about 0.03 inch to about 4.0 inches.-   36. A filter media pack according to any one of characterizations    24-35 wherein:    -   (a) the plurality of first bosses are provided with a boss        density of at least about 0.25 per square inch.-   37. A filter media pack according to any one of characterizations    24-36 wherein:    -   (a) the plurality of second bosses are provided with a boss        density of at least about 0.25 per square inch.-   38. A filter media pack according to any one of characterizations    24-37 wherein:    -   (a) the media construction exhibits a volume asymmetry where one        side exhibits a separation that is 110% or greater compared to        another side, preferably the separation is 110% to 200%, or 130%        to 170%.-   39. A filter media pack according to any one of characterizations    24-37 wherein:    -   (a) the first location comprises a first glue bead adhering the        first media sheet and second media sheet; and    -   (b) the second location comprises a second glue bead adhering        the first media sheet and second media sheet.-   40. A filter media pack of any one of characterizations 24-29    wherein:    -   (a) the plurality of first bosses have a conical sidewall.-   41. A filter media pack according to any one of characterizations    24-40 wherein:    -   (a) the plurality of second bosses have a conical sidewall.-   42. A filter media pack according to any one of characterizations    24-41 wherein:    -   (a) the plurality of first bosses have a domed top.-   43. The filter media pack according to any one of characterizations    24-42 wherein:    -   (a) the plurality of second bosses have a domed top.-   44. A filter media pack according any one of characterizations 24-43    wherein:    -   (a) the filter media pack is in a coiled configuration.-   45. A filter media pack according any one of characterizations 24-43    wherein:    -   (a) the filter media pack is in a stacked configuration.-   46. A filter media pack according to any one of characterizations    24-45, wherein:    -   (a) neither of the first media sheet or the second media sheet        is a fluted or corrugated media sheet.-   47. A filter element comprising:    -   (a) a filter media pack according to any one of        characterizations 1-46;    -   (b) a seal member to prevent fluid from bypassing the filter        media pack when the filter element is installed for use.-   48. A filter element according to characterizations 47, wherein the    seal member comprises a radially directed seal member.-   49. A filter element according to characterizations 47, wherein the    seal member comprises an axially directed seal member.-   50. A filter element according to any one of characterizations    47-49, wherein the seal member is molded to the filter media pack.-   51. A filter element according to any one of characterizations    47-50, wherein the seal member extends around a periphery of the    filter media pack.-   52. A filter element according to any one of characterizations    47-51, wherein the seal member is located spaced away from the first    flow face or the second flow face of the media pack, and is not    located around a periphery of the media pack.-   53. A method of making the filter media pack of any one of    characterizations 1-46 comprising:    -   (a) adhering together at a first location the first media sheet        and second media sheet to form the first separation open at the        second flow face; and    -   (b) rolling or stacking the first media sheet and the second        media sheet together while adhering together at a second        location the first media sheet and second media sheet to form        the second separation open at the first flow face.-   54. A method according to characterization 53 wherein:    -   (a) the step of adhering includes applying adhesive.

It should be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a composition containing “a compound” includes a mixture oftwo or more compounds. It should also be noted that the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

It should also be noted that, as used in this specification and theappended claims, the phrase “configured” describes a system, apparatus,or other structure that is constructed or configured to perform aparticular task or adopt a particular configuration to. The phrase“configured” can be used interchangeably with other similar phrases suchas arranged and configured, constructed and arranged, constructed,manufactured and arranged, and the like.

The above specification provides a complete description of themanufacture and use of the composition of the invention. Since manyembodiments of the invention can be made without departing from thespirit and scope of the invention, the invention resides in the claimshereinafter appended.

What is claimed is:
 1. A filter media pack comprising: (a) a mediaconstruction comprising alternating first media sheet and second mediasheet secured together and forming a first flow face and a second flowface, wherein each of the first media sheet and the second media sheetincludes a first side and a second side; (i) the first media sheetincluding a plurality of first bosses extending from the first mediasheet first side toward the second media sheet to provide a firstseparation between the first media sheet first side and the second mediasheet second side; (ii) the second media sheet including a plurality ofsecond bosses extending from the second media sheet first side in a samedirection as the plurality of first bosses to provide a secondseparation between the second media sheet first side and the first mediasheet second side; (iii) the first media sheet and the second mediasheet secured together at a first location to form the first separationopen at the second flow face, and the first media sheet and the secondmedia sheet secured together at a second location to form the secondseparation open at the first flow face; (b) the media construction beingclosed to passage of unfiltered fluid therethrough from the first flowface to the second flow face or from the second flow face to the firstflow face without filtering passage through the first media sheet or thesecond media sheet; wherein the first separation is greater than thesecond separation; and wherein the first bosses and second bosses havesubstantially circular bases.
 2. A filter media pack according to claim1 wherein: (a) the first media sheet and the second media sheet eachcomprise a first edge that forms the first flow face and a second edgethat forms the second, opposite, flow face, the first location foradhering the first media sheet to the second media sheet is locatedproximate to the first edge, and the second location for adhering thefirst media sheet and the second media sheet is located the second edge.3. A filter media pack according to claim 1 wherein: (a) the first mediasheet includes a plurality of third bosses extending from the firstmedia sheet second side in a direction opposite the plurality of firstbosses to provide the second separation between the first media sheetsecond side and the second media sheet first side.
 4. A filter mediapack according to claim 1 wherein: (a) the second media sheet includes aplurality of fourth bosses extending from the second media sheet secondside in a direction opposite the plurality of first bosses to providethe first separation between the second media sheet second side and thefirst media sheet first side.
 5. A filter media pack according to claim1 wherein: (a) the plurality of first bosses extend away from the firstmedia sheet a distance of at least 0.01 inch.
 6. A filter media packaccording to claim 1 wherein: (a) the plurality of first bosses extendaway from the media sheet a distance of about 0.01 inch to about 0.25inch, or about 0.05 inch to about 0.2 inch.
 7. A filter media packaccording to claim 1 wherein: (a) the plurality of second bosses extendaway from the second media sheet a distance of at least 0.01 inch.
 8. Afilter media pack according to claim 1 wherein: (a) the plurality offirst bosses are provided with a boss density of at least about 0.25 persquare inch.
 9. A filter media pack according to claim 1 wherein: (a)the plurality of second bosses are provided with a boss density of atleast about 0.25 per square inch.
 10. A filter media pack according toclaim 1 wherein: (a) the media construction exhibits a volume asymmetrywhere one side exhibits a separation that is 110% or greater compared toanother side.
 11. A filter media pack according to claim 1 wherein: (a)the plurality of first bosses have a conical sidewall.
 12. A filtermedia pack according to claim 1 wherein: (a) the plurality of secondbosses have a conical sidewall.
 13. A filter media pack according toclaim 1 wherein: (a) the plurality of first bosses have a domed top. 14.A filter media pack according to claim 1 wherein: (a) the plurality ofsecond bosses have a domed top.
 15. A filter media pack according toclaim 1 wherein: (a) neither of the first media sheet nor the secondmedia sheet is a fluted or corrugated media sheet.
 16. A filter mediapack comprising: (a) a media construction comprising alternating firstmedia sheet and a second media sheet secured together and forming afirst flow face and a second flow face, wherein each of the first mediasheet and the second media sheet includes a first side and a secondside; (i) the first media sheet including a plurality of first bossesextending from the first media sheet first side toward the second mediasheet to provide a first separation between the first media sheet firstside and the second media sheet second side, the first bosses have alength and a width that are substantially equal to one another, and aplurality of second bosses extending from the first media sheet secondside in a direction opposite the plurality of first bosses to provide asecond separation between the first media sheet second side and thesecond media sheet first side; (ii) the first media sheet and the secondmedia sheet secured together at a first location to form the firstseparation open at the second flow face, and the first media sheet andthe second media sheet secured together at a second location to form thesecond separation open at the first flow face; (b) the mediaconstruction being closed to passage of unfiltered fluid therethroughfrom the first flow face to the second flow face or from the second flowface to the first flow face without filtering passage through the firstmedia sheet or the second media sheet; wherein the first separation isgreater than the second separation.
 17. A filter media pack according toclaim 16 wherein: (a) the first media sheet and the second media sheeteach comprise a first edge that forms the first flow face and a secondedge that forms the second, opposite, flow face, the first location foradhering the first media sheet to the second media sheet is locatedproximate to the first edge, and the second location for adhering thefirst media sheet and the second media sheet is located proximate to thesecond edge.
 18. A filter media pack according to claim 16 wherein: (a)the second media sheet includes a plurality of third bosses extendingfrom the second media sheet first side in a same direction as theplurality of first bosses to provide the second separation between thesecond media sheet first side and the first media sheet second side. 19.A filter media pack according to claim 16 wherein: (a) the second mediasheet includes a plurality of fourth bosses extending from the secondmedia sheet second side in an opposite direction as the plurality offirst bosses to provide the first separation between the second mediasheet second side and the first media sheet first side.
 20. A filtermedia pack according to claim 16 wherein: (a) the media constructionexhibits a volume asymmetry where one side exhibits a separation that is110% or greater compared to another side.